Nanostructured Thermal Barrier Coatings via Magnetron Sputtering: A Review of Enhanced Performance and Durability

• Published in: International journal of ceramic engineering & science Vol. 7; no. 4
• Main Authors: Altaf, Syed Faizan, Rahman, Atikur, Wani, M. F.
• Format: Journal Article
• Language: English
• Published: Westerville John Wiley & Sons, Inc 01.07.2025; Wiley
• Subjects: Artificial intelligence; Ceramic coatings; Crack propagation; Gas turbines; Grain boundaries; Heat conductivity; High temperature; high‐temperature performance | magnetron sputtering | nanostructured coatings | Superni 718 | thermal barrier coatings; Insulation; Jet engines; Magnetron sputtering; Materials selection; Nanostructure; Oxidation; Oxidation resistance; Parameters; Performance enhancement; Protective coatings; Substrates; Superalloys; Temperature; Thermal barrier coatings; Thermal barriers; Thermal conductivity; Thermal cycling; Thermal insulation; Thermal mismatch; Thermal resistance; Turbines; Yttria-stabilized zirconia; Zirconium dioxide
• ISSN: 2578-3270; 2578-3270
• DOI: 10.1002/ces2.70018

ABSTRACT The current review investigates employing magnetron sputtering techniques to create nanostructured thermal barrier coatings (TBCs) manufactured on the nickel‐based superalloy, Superni 718, which is usually used to manufacture turbine parts that lay under extremely high thermal and mechanical stresses. Versus conventional coating techniques, Magnetron sputtering provides increased density and microstructure control of the coating which translates to better thermal insulation, oxidation resistance and better cyclic properties. Some of the ceramic materials employed include yttria‐stabilized zirconia (YSZ) which has a low thermal conductivity (<1.71 W/m K) in addition to stability at high temperatures approximately 900°C. This is also along with the role of NiCoCrAlY bonding coats in adhesion promotion and minimizational of thermal mismatch. Major depositing parameters like working pressure, substrate temperature and sputtering mode are sharply investigated. Recent advances in high power impulse magnetron sputtering (HiPIMS) as well as the tailored bond coat design discussions are also presented in the review. Lastly, it combines material selection and deposition strategies and determines the gaps in research of in situ diagnostics and multi‐parameter optimization of high‐performance ceramic coating. This review highlights recent advances in magnetron‐sputtered ceramic thermal barrier coatings for Superni 718, emphasizing improved thermal insulation, oxidation resistance, and durability. Key deposition parameters and emerging techniques like HiPIMS are critically discussed with a focus on coating performance under extreme operating conditions.